Tools & Materials

Quick Fix: How to Replace the Switch on a Milwaukee 0240-20 Corded Drill

A bad switch prevents you from working. This article will help guide you through a switch repair so you can keep your tool out of the trash and on your workbench where it belongs.

Switches are some of the first parts to fail in any power tool. And if your switch fails, you will need to replace it. In this article, we show you how to replace the switch on a Milwaukee 0240-20 corded drill. The switch in this drill has several wires attached in different ways. This article will help you understand how to remove and install all the wires and provide a few more useful tips for replacing the switch.

Remove the three screws that secure the back cover and set it aside. This will give you access to the switch.

2. Draw a diagram of the wires

Before you remove the switch, you will want to note where all the wires connect to it. You can draw a diagram or use a digital camera or phone to note the wire positions.

3. Begin removing the wires

Now you can begin removing the wires. On the Milwaukee 0240-20 drill, the wires connect to the switch three different ways:

Allen-wrench screws: Two of the wires are secured by small Allen-wrench screws. Loosen these screws to remove the wires.

Trap doors: Two of the wires are secured with trap doors. Use a pick to trigger the release and then pull the wires free from the switch.

Tabs: The other four wires simply slide into place with tabs. You can use pliers to pull them off their tabs to finish freeing up the switch.

4. Install the new switch

Now use your diagram to install the new switch. Slide the Allen-wrench wires into place then tighten the screws. The trap door wires will click into their slots, and you can slide tab wires into place with your pliers.

Once you have all the wires connected, set the switch into place then route the wires so they won't get pinched when you re-install the back cover.

5. Re-install the back cover

Now set the back cover into place and tighten the screws to finalize the repair.

And that's how you replace the switch on your Milwaukee 0240-20 corded drill. This repair should only take about 15 minutes, especially if you take the time to draw a diagram or take a quick digital photo of your switch's wiring.